Jeep Wrangler TJ. Manual — part 441
(4) Remove the upper radiator hose and coolant
recovery hose (Fig. 4).
(5) Remove the lower radiator hose.
(6) Remove upper radiator support retaining bolts
and remove radiator support.
(7) Remove the fan assembly from the water pump
(Refer to 7 - COOLING/ENGINE/FAN DRIVE VIS-
COUS CLUTCH - REMOVAL).
(8) Remove the fan shroud (Fig. 4).
(9) Disconnect the transmission fluid cooler lines
(automatic transmission).
(10) Discharge the A/C system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE).
(11) Remove the service valves and cap the com-
pressor ports.
(12) Remove the radiator (Refer to 7 - COOLING/
ENGINE/RADIATOR - REMOVAL) or radiator/con-
denser (if equipped with A/C).
(13) Disconnect the heater hoses at the engine
thermostat housing and water pump (Fig. 4).
(14) Disconnect the accelerator cable, transmission
line pressure cable and speed control cable (if
equipped) from the throttle body (Fig. 5).
(15) Remove cables from the bracket and secure
out of the way.
(16) Disconnect the body ground at the engine.
(17) Disconnect
the
following
connectors
and
secure their harness out of the way.
• Power steering pressure switch
• Coolant temperature sensor
• Six (6) fuel injector connectors
• Intake air temperature sensor
• Throttle position sensor
• Map sensor
• Crankshaft position sensor
• Oxygen sensor
• Camshaft position sensor
• Generator connector and B+ terminal wire
(18) Disconnect the coil rail electrical connections
and the oil pressure switch connector.
(19) Perform the fuel pressure release procedure
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY -
STANDARD PROCEDURE).
(20) Disconnect the fuel supply line at the injector
rail (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/
QUICK CONNECT FITTING - STANDARD PROCE-
DURE).
(21) Remove the fuel line bracket from the intake
manifold.
(22) Remove the air cleaner assembly (Fig. 6).
(23) Disconnect the hoses from the fittings at the
steering gear.
(24) Drain the pump reservoir.
Fig. 4 Upper Radiator Hose, Coolant Recovery
Hose, Fan Shroud
1 - UPPER RADIATOR HOSE
2 - HEATER HOSES
3 - FAN SHROUD
4 - COOLANT RECOVERY HOSE
Fig. 5 Accelerator Cable, Vehicle Speed Control
Cable, Automatic Transmission
1 - ACCELERATOR CABLE
2 - SPEED CONTROL CABLE
3 - QUICK-CONNECT FUEL LINES
4 - AUTOMATIC TRANSMISSION CONTROL CABLE
TJ
ENGINE 4.0L
9 - 79
ENGINE 4.0L (Continued)
(25) Cap the fittings on the hoses and steering
gear to prevent foreign objects from entering the sys-
tem.
(26) Raise and support the vehicle.
(27) Disconnect the wires from the engine starter
motor solenoid.
(28) Remove the engine starter motor (Refer to 8 -
ELECTRICAL/STARTING/STARTER
MOTOR
-
REMOVAL).
(29) Disconnect
the
oxygen
sensor
from
the
exhaust pipe.
(30) Disconnect the exhaust pipe from the mani-
fold.
(31) Remove the exhaust pipe support.
(32) Remove the bending brace (Refer to 9 -
ENGINE/ENGINE
BLOCK/WINDAGE
TRAY
/
STRUCT SUPPORT - REMOVAL).
(33) Remove the engine flywheel/converter housing
access cover.
(34) Mark the converter and drive plate location.
(35) Remove the converter-to-drive plate bolts.
(36) Remove the upper engine flywheel/converter
housing bolts and loosen the bottom bolts.
(37) Remove the engine mount cushion-to-engine
compartment bracket bolts.
(38) Lower the vehicle.
(39) Attach a lifting device to the engine.
(40) Raise the engine off the front supports.
(41) Place a support or floor jack under the con-
verter (or engine flywheel) housing.
(42) Remove the remaining converter (or engine
flywheel) housing bolts.
(43) Lift the engine out of the engine compart-
ment.
INSTALLATION
CAUTION: When installing the engine into a vehicle
equipped with an automatic transmission, be care-
ful not to damage the trigger wheel on the engine
flywheel.
(1) Attach a lifting device to the engine and lower
the engine into the engine compartment. For easier
installation, it may be necessary to remove the
engine mount bracket as an aid in alignment of the
engine to the transmission.
(2) Align the transmission torque converter hous-
ing with the engine.
(3) Loosely install the converter housing lower
bolts and install the next higher bolt and nut on each
side.
(4) Tighten all 4 bolts finger tight.
(5) Install the engine mount brackets (if removed).
(6) Lower the engine and engine mount brackets
onto the engine compartment cushions. Install the
bolts and finger tighten the nuts.
(7) Remove the engine lifting device.
(8) Raise and support the vehicle.
(9) Install the remaining engine flywheel/converter
housing bolts. Tighten all bolts to 38 N·m (28 ft. lbs.)
torque.
(10) Install the converter-to-drive plate bolts.
(11) Ensure the installation reference marks are
aligned.
(12) Install the engine flywheel/converter housing
access cover.
(13) Install the exhaust pipe support and tighten
the screw.
(14) Install the engine bending brace (Refer to 9 -
ENGINE/ENGINE
BLOCK/WINDAGE
TRAY
/
STRUCT SUPPORT - INSTALLATION).
(15) Tighten the engine mount-to-bracket bolts.
(16) Connect the vehicle speed sensor wire connec-
tions and tighten the screws.
(17) Connect the exhaust pipe to the manifold.
(18) Install the engine starter motor (Refer to 8 -
ELECTRICAL/STARTING/STARTER
MOTOR
-
INSTALLATION).
(19) Connect the wires to the engine starter motor
solenoid.
(20) Lower the vehicle.
(21) Connect vacuum hoses and wire connectors
disconnected during engine removal.
(22) Remove protective caps from the power steer-
ing hoses.
Fig. 6 Air Cleaner Assembly & Power Steering Pump
1 - POWER STEERING PUMP
2 - AIR CLEANER ASSEMBLY
9 - 80
ENGINE 4.0L
TJ
ENGINE 4.0L (Continued)
(23) Connect the hoses to the fittings at the steer-
ing gear. Tighten the nut to 52 N·m (38 ft. lbs.)
torque.
(24) Fill the pump reservoir with fluid (Refer to 19
- STEERING/PUMP - STANDARD PROCEDURE).
(25) Inspect the fuel supply line o-ring(s) and
replace if necessary. Connect fuel supply line to injec-
tior rail and verify connection by pulling outward on
the line.
(26) Install the fuel line bracket to the intake
manifold.
(27) Connect the coil rail electrical connectors and
oil pressure switch connector.
(28) Connect the following electrical connectors:
• Power steering pressure switch
• Coolant temperature sensor
• Six (6) fuel injector connectors
• Intake air temperature sensor
• Throttle position sensor
• Map sensor
• Crankshaft position sensor
• Oxygen sensor
• Camshaft position sensor
• Generator connector and B+ terminal wire
(29) Connect all previously removed vacuum hoses.
(30) Connect the body ground strap.
(31) Install the throttle, transmission line pres-
sure, and speed control cables to their mounting
bracket and connect them to the throttle body.
(32) Connect the heater hoses at the engine ther-
mostat housing and water pump.
(33) Install the fan assembly to the water pump
(Refer to 7 - COOLING/ENGINE/FAN DRIVE VIS-
COUS CLUTCH - INSTALLATION).
(34) Place the fan shroud in position over the fan.
(35) Install
the
radiator
or
radiator/condenser
(Refer
to
7
-
COOLING/ENGINE/RADIATOR
-
INSTALLATION).
(36) Connect the service valves to the A/C com-
pressor ports, if equipped with A/C.
(37) Charge the air conditioner system (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE).
(38) Connect the radiator hoses and automatic
transmission fluid cooler pipes, if equipped.
(39) Install the fan shroud to the radiator or radi-
ator/condenser (if equipped with A/C).
(40) Install upper radiator support.
(41) Connect the upper radiator hose and tighten
the clamp.
(42) Connect the lower radiator hose and tighten
the clamp.
(43) Fill crankcase with engine oil (Refer to
LUBRICATION & MAINTENANCE - SPECIFICA-
TIONS).
(44) Fill the cooling system (Refer to 7 - COOLING
- STANDARD PROCEDURE).
(45) Align the hood to the scribe marks. Install the
hood.
(46) Install the air cleaner assembly.
(47) Install the battery and connect the battery
cable.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.
(48) Start the engine, inspect for leaks and correct
the fluid levels, as necessary.
SPECIFICATIONS
ENGINE - 4.0L
GENERAL DESCRIPTION
DESCRIPTION
SPECIFICATION
Engine Type
In-Line 6 Cylinder
Displacement
4.0 Liters / 4000 cc
242 ( Cubic Inches)
Bore
98.4 mm (3.88 in.)
Stroke
86.69 mm (3.413 in.)
Compression Ratio
8.8:1
Firing Order
1-5-3-6-2-4
Lubrication
Pressure Feed-Full
Flow-Filtration
Cooling System
Liquid Cooled-Forced
Circulation
Cylinder Block
Cast Iron
Crankshaft
Cast Nodular Iron
Cylinder Head
Cast Iron
Camshaft
Cast Iron
Pistons
Aluminum Alloy
Combustion Chamber
Dual-Quench
Connecting Rods
Cast Malleable Iron
TJ
ENGINE 4.0L
9 - 81
ENGINE 4.0L (Continued)
CYLINDER BLOCK
DESCRIPTION
SPECIFICATION
Metric
Standard
CylinderBore
Diameter
98.45 - 98.48
mm
3.8759 - 3.8775
in.
Out of Round
(MAX)
0.025 mm
0.001 in.
Taper (MAX)
0.025 mm
0.001 in.
Deck Height
240.03 - 240.18
mm
9.450 - 9.456 in.
Deck Clearance
(Below Deck)
0.546 mm
0.0215 in.
Tappet Bore
Diameter
23.000 - 23.025
mm
0.9055 - 0.9065
Flatness
0.03 mm per 25
mm
0.001 in. per 1
in.
0.05 mm per
152 mm
0.002 in. per 6
in.
Flatness (MAX)
0.20 mm (MAX)
for total length
0.008 in. MAX)
for total length
Main Bearing
Bore Diameter
68.351 - 68.376
mm
2.691 - 2.692 in.
PISTONS
DESCRIPTION
SPECIFICATION
Metric
Standard
Weight (Less
Pin)
417 - 429 grams
14.7 - 15.1 oz
Piston Pin Bore
Diameter
23.650 - 23.658
mm
0.9312 - 0.9315
in.
Piston Pin To
Bore ( Centerline
To Piston Top)
40.61 - 40.72
mm
1.599 - 1.603 in.
Piston To Bore
Clearance
0.018 - 0.038
mm
0.0008 - 0.0015
in.
Piston Ring
Groove Height
Compression
Rings
1.530 - 1.555
mm
0.0602 - 0.0612
in.
Oil Control Rings
4.035 - 4.060
mm
0.1589 - 0.1598
in.
Piston Ring
Groove Diameter
No. 1
Compression
88.39 - 88.65
mm
3.48 - 3.49 in
DESCRIPTION
SPECIFICATION
Metric
Standard
No. 2
Compression
87.63 - 87.88
mm
3.45 - 3.46 in.
No. 3 Oil Control
89.66 - 89.92
mm
3.53 - 3.54 in.
PISTON PINS
DESCRIPTION
SPECIFICATION
Metric
Standard
Piston To Pin
Clearance
0.0102 - 0.0208
mm
0.0005 - 0.0009
in.
Diameter
23.637 - 23.640
mm
0.9306 - 0.9307
in.
Piston-Pin To
Connecting Rod
(Press Fit)
8.9kN
2000 lbf.
PISTON RINGS
DESCRIPTION
SPECIFICATION
Metric
Standard
Ring Gap
Top
Compression
Ring
0.229 - 0.610
mm
0.0090 - 0.0240
in.
Second
Compression
Ring
0.483 - 0.965
mm
0.0190 - 0.0380
in.
Oil Control
(Steel Rails)
0.254 - 1.500
mm
0.010 - 0.060 in.
Side Clearance
Top
Compression
Ring
.042 - .084 mm
0.0017 - 0.0033
in.
Second
Compression
Ring
0.042 - 0.084
mm
0.0017 - 0.0033
in.
Oil Ring (Steel
Ring)
.06 - .21 mm
.0024 - .0083 in.
9 - 82
ENGINE 4.0L
TJ
ENGINE 4.0L (Continued)
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